0204588 EVINRUDE WASHER,Steel,.042"

Table 1
Revision Summary of Changes
02 Part number for oil cooling jet added to Table 2 for engine less than 410 hp A new cylinder pack is now available for engines that use 9Y-4004 Piston Body As or the 290-0017 Piston Body As. In applications less than 410 hp, the 378-0509 Piston Body As has been designed with an improved skirt to prevent early hour seizure. The 20R-1115 Cylinder Pack As is now available for 3406B models with the narrow crank journal connecting rod. The 20R-1116 Cylinder Pack As is now available for 3406C models with the wide crank journal connecting rod. The new piston is similar in weight and uses the same oil jet as 9Y-4004 Piston Body As and 290-0017 Piston Body As. Cylinder packs can be installed in engines with older design pistons, 9Y-4004 Piston Body As and 290-0017 Piston Body As.When the engine operates at high horsepowers or high temperatures, seizures can occur in the four corners within the cylinders. Engines with greater than 410 HP can upgrade all 6 cylinder packs during overhaul or engine repair. Use the upgrade cylinder packs in sets of 6. The upgrade cylinder packs contain a gallery cooled piston 160-1131 Piston Body As that replaces 9Y-4004 Piston Body As, 290-0017 Piston Body As, or 378-0509 Piston Body As. Refer to Table 2for the correct part numbers. The upgrade cylinder pack contains a gallery cooled piston. The gallery cooled piston requires replacement of the cooling jet with a single configuration to a cooling jet that has dual configuration. 7W-4990 Piston Cooling Jet As must be replaced with the 7E-3632 Piston Cooling Jet As or the 151-5928 Piston Cooling Jet As. There are two different sizes of cooling jets. Use 7E-3632 Piston Cooling Jet As for a 8.2 mm (3/8 inch) bolt hole. Use 151-5928 Piston Cooling Jet As for a 10.2 mm (7/16 inch) bolt hole.The upgrade cylinder packs will also require the oil pump pressure to increase to support the upgrade cooling jets. The 0R-9448 Engine Oil Pump Gp must be replaced with 0R-9449 Engine Oil Pump Gp to increase the relief valve pressure setting from 483 kPa (70 psi) to 621 kPa (90 psi). Brakesaver applications use 0R-9697 Engine Oil Pump Gp must be replaced with 10R-0428 Engine Oil Pump Gp.Note: The relief valve pressure setting can be increased on the existing oil pump by replacing the 9Y-1800 Retainer with the 9Y-1792 Retainer.Note: During engine overhaul or repair, ensure that cylinder pack is sufficiently lubricated with engine oil during installation. Proper lubrication of the piston, liner, and the piston pin joint between the piston and connecting rod is important to prevent seizure. During engine break-in, allow additional 10 minutes of near zero load at 1,000 rpm prior to putting the engine under load.Note: Engines with a coolant surge tank require special venting of the tank when testing engine on a dyno to prevent piston seizure. Piston seizure can occur when the surge tank fills with steam when not properly vented as the engine warms up. Once engine is at operating temperature, the thermostat opens and the steam trapped in the surge tank goes through the engine causing coolant to be displaced. Fire Pump applications contain a coolant surge tank.
Table 2
Less than 410 hp 20R-1115 Cylinder Pack As
(Narrow Journal Rod) 20R-1116 Cylinder Pack As
(Wide Journal Rod) 9Y-4004 or 290-0017 or 378-0509
Piston Body 7W-4990 Piston Cooling Jet As (3/8 in) 290-6567 Piston Cooling Jet As (7/16 in) 0R-9448 Engine Oil Pump Gp 0R-9697 Oil Pump(3)
Greater than 410 hp 10R-3201 Cylinder Pack As
(Narrow Journal Rod) 0R-4178 Cylinder Pack As
(Wide Journal Rod) 160-1131 Piston Body 7E-3632 Piston Cooling Jet As (1)
151-5928 Piston Cooling Jet As (2) 0R-9449 Engine Oil Pump Gp 10R-0428 Oil Pump(3)
(1) Use 7E-3632 Piston Cooling Jet As with a 8.2 mm (3/8 inch) bolt hole.
(2) Use 151-5928 Piston Cooling Jet As with a 10.2 mm (7/16 inch) bolt hole.
(3) This engine oil pump is only used with brake saver systems.The following procedure gives the installation instructions for the 160-9874 Gasket Kit. Ensure that the proper color and the proper part number of the seals are positioned in the appropriate grooves in the Cylinder Liner . Also ensure that the proper lubricants are used.
Failure to use the correct oil jet and the correct oil pump could cause engine failure.
Note: Improper assembly of the cylinder liner will result in premature failure of the sealing system. Ensure that liner seals are properly lubricated during installation to prevent O-rings from being cut or rolling out of the O-ring groove on the liner. Rolled O-rings will cause distortion of the liner.Installation Instructions for the Gasket Kit
Table 3
Required Tools Qty
5P-3975 Rubber Lubricant 1
2P-8260 Cylinder Liner Installer 1
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Check the cylinder liner projection. Refer to Testing and Adjusting, "Cylinder Liner Projection - Inspect" for the proper projection.
Check for erosion on the tapered portion of the bore for each cylinder liner on the cylinder block. Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8371, "Salvage of Cylinder Block Liner Bores for 3400 C15 and C18 Family of Engines".
Illustration 1 g01248777
Location of the cylinder liner seals
Apply 5P-3975 Rubber Lubricant on the ring grooves on the